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CoAspire · 1 day ago

Senior Electrical Engineer

Manassas, VA

Full-time

Onsite

Senior Level, Lead/Staff

8+ years exp

CoAspire is a cutting-edge defense manufacturing leader in Northern Virginia, specializing in the precision assembly of advanced weapons systems. The Senior Electrical Engineer will work directly on the production floor to drive electrical/avionics assembly process optimization and support high-rate manufacturing while ensuring compliance with safety and performance standards.

ConsultingCyber SecurityInformation TechnologyInternet of Things

No H1B

Security Clearance Required

U.S. Citizen Only

Hiring Manager

Matt Fisher

Responsibilities

Lead electrical/avionics Design-for-Manufacturing/Assembly (DFM/DFA) reviews and value engineering initiatives to simplify harness designs, standardize connectors and components, reduce wire count/routing complexity, and minimize CCA variants

Identify and qualify lower-cost alternative connectors, cables, CCAs, power supplies, RF components, and electronics (COTS/mil-spec) that meet form/fit/function, EMI/EMC, environmental, and ITAR requirements while achieving cost savings

Optimize electrical assembly sequences, tooling, fixtures, work instructions, and test procedures to cut assembly and test time, reduce labor hours, and improve first-pass yield on the production line

Perform root-cause analysis on electrical production issues (harness fit/routing, continuity failures, EMI problems, non-conformances, rework) and implement corrective actions, including ECNs and schematic/redline updates

Collaborate with supply chain and suppliers on make-vs-buy decisions for harnesses/CCAs, vendor qualifications, obsolescence management, and long-term agreements to secure cost-effective, reliable sources

Support and maintain electrical manufacturing bills of materials (MBOMs), cable drawings, schematics, and test documentation in the ERP/PLM system

Conduct time studies, line balancing, and capacity analyses for electrical assembly and test stations; mentor technicians and junior engineers on the floor

Ensure all changes comply with AS9100D and all company and customer requirements

Qualification

Electrical EngineeringAerospace/Defense ExperienceCost Reduction ProgramsECN Release in PLM/ERPMilitary-grade ConnectorsCable/Harness FabricationElectrical Manufacturing ProcessesFloor PresenceCommunication

Required

8+ years of hands-on electrical/electronics manufacturing or production engineering experience in aerospace/defense

Bachelor's degree in Electrical Engineering, Electronics Engineering, or related field

Experience of cost-reduction and assembly/test time improvement programs (e.g., harness simplification, connector standardization, CCA redesign-for-cost, COTS insertion)

Strong ability to read and redline schematics, harness drawings, and PCB layouts; experienced releasing ECNs in PLM/ERP environments (e.g., Windchill)

Strong knowledge of military-grade and/or COTS connectors, cable/harness fabrication (IPC/WHMA-A-620), RF/coaxial assemblies, power distribution, and EMI shielding techniques

Familiarity with electrical manufacturing processes including crimping, soldering, automated wire processing, conformal coating, and functional/ESS testing

U.S. citizenship and current Secret clearance (or ability to obtain/maintain one)

Excellent communication and floor presence; comfortable presenting data-driven recommendations to leadership and suppliers